Effect of Interface Form on Creep Failure and Life of Dissimilar Metal Welds Involving Nickel-Based Weld Metal and Ferritic Base Metal

For dissimilar metal welds(DMWs)involving nickel-based weld metal(WM)and ferritic heat resistant steel base metal(BM)in power plants,there must be an interface between WM and BM,and this interface suffers mechanical and microstructure mismatches and is often the rupture location of premature failure.In this study,a new form of WM/BM interface form,namely double Y-type interface was designed for the DMWs.Creep behaviors and life of DMWs containing double Y-type interface and conventional I-type interface were compared by finite element analysis and creep tests,and creep failure mechanisms were investigated by stress-strain analysis and microstructure characterization.By applying double Y-type interface instead of conventional I-type interface,failure location of DMW could be shifted from the WM/ferritic heat-affected zone(HAZ)interface into the ferritic HAZ or even the ferritic BM,and the failure mode change improved the creep life of DMW.The interface premature failure of I-type interface DMW was related to the coupling effect of microstructure degradation,stress and strain concentrations,and oxide notch on the WM/HAZ interface.The creep failure of double Y-type interface DMW was the result of Type IV fracture due to the creep voids and micro-cracks on fine-grain boundaries in HAZ,which was a result of the matrix softening of HAZ and lack of precipitate pinning at fine-grain boundaries.The double Y-type interface form separated the stress and strain concentrations in DMW from the WM/HAZ interface,preventing the trigger effect of oxide notch on interface failure and inhibiting the interfacial microstructure cracking.It is a novel scheme to prolong creep life and enhance reliability of DMW,by means of optimizing the interface form,decoupling the damage factors from WM/HAZ interface,and then changing the failure mechanism and shifting the failure location.

Tribological Behaviors of Electroless Nickel-Boron Coating on Titanium Alloy Surface

Titanium alloys are excellent structural materials in engineering fields,but their poor tribological properties limit their further applications.Electroless plating is an effective method to enhance the tribological performance of alloys,but it is difficult to efficiently apply to titanium alloys,due to titanium alloy’s strong chemical activity.In this work,the electroless Nickel-Boron(Ni-B)coating was successfully deposited on the surface of titanium alloy(Ti-6AL-4V)via a new pre-treatment process.Then,linearly reciprocating sliding wear tests were performed to evaluate the tribological behaviors of titanium alloy and its electroless Ni-B coatings.It was found that the Ni-B coatings can decrease the wear rate of the titanium alloy from 19.89×10^(−3)mm^(3)to 0.41×10^(−3)mm^(3),which attributes to the much higher hardness of Ni-B coatings.After heat treatment,the hardness of Ni-B coating further increases corresponding to coating crystallization and hard phase formation.However,heat treatment does not improve the tribological performance of Ni-B coating,due to the fact that higher brittleness and more severe oxidative wear exacerbate the damage of heat-treated coatings.Furthermore,the Ni-B coatings heat-treated both in air and nitrogen almost present the same tribological performance.The finding of this work on electroless coating would further extend the practical applications of titanium alloys in the engineering fields.

Microstructure,Corrosion and Mechanical Properties of Medium-Thick 6061-T6 Alloy/T2 Pure Cu Dissimilar Joints Produced by Double Side Friction Stir Z Shape Lap-Butt Welding

A novel double side friction stir Z shape lap-butt welding(DS-FSZW)process was proposed to achieve excellent mechanical properties of Al/Cu medium-thick dissimilar joints.The influence of welding parameters on weld microstructure and properties of DS-FSZW joint were systematically investigated.It indicated that defect-free medium-thick Al/Cu DS-FSZW joint could be achieved under an optimal welding parameter.DS-FSZW joint was prone to form void defects in the bottom of the second-pass weld.The recrystallization mechanisms at the top and middle of the weld nugget zone(WNZ)were continuous dynamic recrystallization(CDRX)and geometric dynamic recrystallization(GDRX).While the major recrystallization mechanism at the bottom of the WNZ was GDRX.DS-FSZW joint of the optimal welding condition with 850 r/min-400 mm/min was produced with a continuous thin and crack-free IMCs layer at the Al/Cu interface,and the maximum tensile strength of this joint is 160.57 MPa,which is equivalent to 65.54%of pure Cu base material.Moreover,the corrosion resistance of Al/Cu DS-FSZW joints also achieved its maximum value at the optimal welding parameter of 850 r/min-400 mm/min.It demonstrates that the DS-FSZW process can simultaneously produce medium-thick Al/Cu joints with excellent mechanical performance and corrosion resistance.

Fiber Bundle Topology Optimization for Surface Flows

This paper presents a topology optimization approach for the surface flows on variable design domains.Via this approach,the matching between the pattern of a surface flow and the 2-manifold used to define the pattern can be optimized,where the 2-manifold is implicitly defined on another fixed 2-manifold named as the base manifold.The fiber bundle topology optimization approach is developed based on the description of the topological structure of the surface flow by using the differential geometry concept of the fiber bundle.The material distribution method is used to achieve the evolution of the pattern of the surface flow.The evolution of the implicit 2-manifold is realized via a homeomorphous map.The design variable of the pattern of the surface flow and that of the implicit 2-manifold are regularized by two sequentially implemented surface-PDE filters.The two surface-PDE filters are coupled,because they are defined on the implicit 2-manifold and base manifold,respectively.The surface Navier-Stokes equations,defined on the implicit 2-manifold,are used to describe the surface flow.The fiber bundle topology optimization problem is analyzed using the continuous adjoint method implemented on the first-order Sobolev space.Several numerical examples have been provided to demonstrate this approach,where the combination of the viscous dissipation and pressure drop is used as the design objective.

Multi-Physics Coupled Acoustic-Mechanics Analysis and Synergetic Optimization for a Twin-Fluid Atomization Nozzle

Fine particulate matter produced during the rapid industrialization over the past decades can cause significant harm to human health.Twin-fluid atomization technology is an effective means of controlling fine particulate matter pollution.In this paper,the influences of the main parameters on the droplet size,effective atomization range and sound pressure level(SPL)of a twin-fluid nozzle(TFN)are investigated,and in order to improve the atomization performance,a multi-objective synergetic optimization algorithm is presented.A multi-physics coupled acousticmechanics model based on the discrete phase model(DPM),large eddy simulation(LES)model,and Ffowcs Williams-Hawkings(FW-H)model is established,and the numerical simulation results of the multi-physics coupled acoustic-mechanics method are verified via experimental comparison.Based on the analysis of the multi-physics coupled acoustic-mechanics numerical simulation results,the effects of the water flow on the characteristics of the atomization flow distribution were obtained.A multi-physics coupled acoustic-mechanics numerical simulation result was employed to establish an orthogonal test database,and a multi-objective synergetic optimization algorithm was adopted to optimize the key parameters of the TFN.The optimal parameters are as follows:A gas flow of 0.94 m^(3)/h,water flow of 0.0237 m^(3)/h,orifice diameter of the self-excited vibrating cavity(SVC)of 1.19 mm,SVC orifice depth of 0.53 mm,distance between SVC and the outlet of nozzle of 5.11 mm,and a nozzle outlet diameter of 3.15 mm.The droplet particle size in the atomization flow field was significantly reduced,the spray distance improved by 71.56%,and the SPL data at each corresponding measurement point decreased by an average of 38.96%.The conclusions of this study offer a references for future TFN research.

Modeling and Validation of Diamagnetic Rotor Levitated by Permanent Magnetics

As an innovative,low-power consuming,and low-stiffness suspension approach,the diamagnetic levitation technique has attracted considerable interest because of its potential applicability in miniaturized mechanical systems.The foundation of a diamagnetic levitation system is mathematical modeling,which is essential for operating performance optimization and stability prediction.However,few studies on systematic mathematical modeling have been reported.In this study,a systematic mathematical model for a disc-shaped diamagnetically levitated rotor on a permanent magnet array is proposed.Based on the proposed model,the magnetic field distribution characteristics,diamagnetic levitation force characteristics(i.e.,levitation height and stiffness),and optimized theoretical conditions for realizing stable levitation are determined.Experiments are conducted to verify the feasibility of the proposed mathematical model.Theoretical predictions and experimental results indicate that increasing the levitation height enlarges the stable region.Moreover,with a further increase in the rotor radius,the stable regions of the rotor gradually diminish and even vanish.Thus,when the levitation height is fixed,a moderate rotor radius permits stable levitation.This study proposes a mathematical modeling method for a diamagnetic levitation system that has potential applications in miniaturized mechanical systems.

Development of Fixture Layout Optimization for Thin-Walled Parts:A Review

An increasing number of researchers have researched fixture layout optimization for thin-walled part assembly during the past decades.However,few papers systematically review these researches.By analyzing existing literature,this paper summarizes the process of fixture layout optimization and the methods applied.The process of optimization is made up of optimization objective setting,assembly variation/deformation modeling,and fixture layout optimization.This paper makes a review of the fixture layout for thin-walled parts according to these three steps.First,two different kinds of optimization objectives are introduced.Researchers usually consider in-plane variations or out-of-plane deformations when designing objectives.Then,modeling methods for assembly variation and deformation are divided into two categories:Mechanism-based and data-based methods.Several common methods are discussed respectively.After that,optimization algorithms are reviewed systematically.There are two kinds of optimization algorithms:Traditional nonlinear programming and heuristic algorithms.Finally,discussions on the current situation are provided.The research direction of fixture layout optimization in the future is discussed from three aspects:Objective setting,improving modeling accuracy and optimization algorithms.Also,a new research point for fixture layout optimization is discussed.This paper systematically reviews the research on fixture layout optimization for thin-walled parts,and provides a reference for future research in this field.

Heuristic Expanding Disconnected Graph:A Rapid Path Planning Method for Mobile Robots

Existing mobile robots mostly use graph search algorithms for path planning,which suffer from relatively low planning efficiency owing to high redundancy and large computational complexity.Due to the limitations of the neighborhood search strategy,the robots could hardly obtain the most optimal global path.A global path planning algorithm,denoted as EDG*,is proposed by expanding nodes using a well-designed expanding disconnected graph operator(EDG)in this paper.Firstly,all obstacles are marked and their corners are located through the map pre-processing.Then,the EDG operator is designed to find points in non-obstruction areas to complete the rapid expansion of disconnected nodes.Finally,the EDG*heuristic iterative algorithm is proposed.It selects the candidate node through a specific valuation function and realizes the node expansion while avoiding collision with a minimum offset.Path planning experiments were conducted in a typical indoor environment and on the public dataset CSM.The result shows that the proposed EDG*reduced the planning time by more than 90%and total length of paths reduced by more than 4.6%.Compared to A*,Dijkstra and JPS,EDG*does not show an exponential explosion effect in map size.The EDG*showed better performance in terms of path smoothness,and collision avoidance.This shows that the EDG*algorithm proposed in this paper can improve the efficiency of path planning and enhance path quality.

On the Polygonal Wear Evolution of Heavy-Haul Locomotive Wheels due to Wheel/Rail Flexibility and Its Mitigation Measures

Wheel polygonal wear can immensely worsen wheel/rail interactions and vibration performances of the train and track,and ultimately,lead to the shortening of service life of railway components.At present,wheel/rail medium-or high-frequency frictional interactions are perceived as an essential reason of the high-order polygonal wear of railway wheels,which are potentially resulted by the flexible deformations of the train/track system or other external excitations.In this work,the effect of wheel/rail flexibility on polygonal wear evolution of heavy-haul locomotive wheels is explored with aid of the long-term wheel polygonal wear evolution simulations,in which different flexible modeling of the heavy-haul wheel/rail coupled system is implemented.Further,the mitigation measures for the polygonal wear of heavy-haul locomotive wheels are discussed.The results point out that the evolution of polygonal wear of heavy-haul locomotive wheels can be veritably simulated with consideration of the flexible effect of both wheelset and rails.Execution of mixed-line operation of heavy-haul trains and application of multicut wheel re-profiling can effectively reduce the development of wheel polygonal wear.This research can provide a deep-going understanding of polygonal wear evolution mechanism of heavy-haul locomotive wheels and its mitigation measures.

A Modified Iterative Learning Control Approach for the Active Suppression of Rotor Vibration Induced by Coupled Unbalance and Misalignment

This paper proposes a modified iterative learning control(MILC)periodical feedback-feedforward algorithm to reduce the vibration of a rotor caused by coupled unbalance and parallel misalignment.The control of the vibration of the rotor is provided by an active magnetic actuator(AMA).The iterative gain of the MILC algorithm here presented has a self-adjustment based on the magnitude of the vibration.Notch filters are adopted to extract the synchronous(1×Ω)and twice rotational frequency(2×Ω)components of the rotor vibration.Both the notch frequency of the filter and the size of feedforward storage used during the experiment have a real-time adaptation to the rotational speed.The method proposed in this work can provide effective suppression of the vibration of the rotor in case of sudden changes or fluctuations of the rotor speed.Simulations and experiments using the MILC algorithm proposed here are carried out and give evidence to the feasibility and robustness of the technique proposed.

A Coordinate-Free Approach to the Design of Generalized Griffis-Duffy Platforms

Architectural singularity belongs to the Type II singularity,in which a parallel manipulator(PM)gains one or more degrees of freedom and becomes uncontrollable.PMs remaining permanently in a singularity are beneficial for linearto-rotary motion conversion.Griffis-Duffy(GD)platform is a mobile structure admitting a Bricard motion.In this paper,we present a coordinate-free approach to the design of generalized GD platforms,which consists in determining the shape and attachment of both the moving platform and the fixed base.The generalized GD platform is treated as a combination of six coaxial single-loop mechanisms under the same constraints.Owing to the inversion,hidden in the geometric structure of these single-loop mechanisms,the mapping from a line to a circle establishes the geometric transformation between the fixed base and the moving platform based on the center of inversion,and describes the shape and attachment of the generalized GD platform.Moreover,the center of inversion not only identifies the location of rotation axis,but also affects the shape of the platform mechanism.A graphical construction of generalized GD platforms using inversion,proposed in the paper,provides geometrically feasible solutions of the manipulator design for the requirement of the location of rotation axis.

State Estimation of Drive-by-Wire Chassis Vehicle Based on Dual Unscented Particle Filter Algorithm

Accurate vehicle dynamic information plays an important role in vehicle driving safety.However,due to the characteristics of high mobility and multiple controllable degrees of freedom of drive-by-wire chassis vehicles,the current mature application of traditional vehicle state estimation algorithms can not meet the requirements of drive-by-wire chassis vehicle state estimation.This paper proposes a state estimation method for drive-by-wire chassis vehicle based on the dual unscented particle filter algorithm,which make full use of the known advantages of the four-wheel drive torque and steer angle parameters of the drive-by-wire chassis vehicle.In the dual unscented particle filter algorithm,two unscented particle filter transfer information to each other,observe the vehicle state information and the tire force parameter information of the four wheels respectively,which reduce the influence of parameter uncertainty and model parameter changes on the estimation accuracy during driving.The performance with the dual unscented particle filter algorithm,which is analyzed in terms of the time-average square error,is superior of the unscented Kalman filter algorithm.The effectiveness of the algorithm is further verified by driving simulator test.In this paper,a vehicle state estimator based on dual unscented particle filter algorithm was proposed for the first time to improve the estimation accuracy of vehicle parameters and states.

Bulging Distortion of Austenitic Stainless Steel Sheet on the Partially Penetrated Side of Non-Penetration Lap Laser Welding Joint

Non-penetration laser welding of lap joints in austenitic stainless steel sheets is commonly preferred in fields where the surface quality is of utmost importance.However,the application of non-penetration welded austenitic stainless steel parts is limited owing to the micro bulging distortion that occurs on the back surface of the partial penetration side.In this paper,non-penetration lap laser welding experiments,were conducted on galvanized and SUS304 austenitic stainless steel plates using a fiber laser,to investigate the mechanism of bulging distortion.A comparative experiment of DC01 galvanized steel-Q235 carbon steel lap laser welding was carried out,and the deflection and distortion profile of partially penetrated side of the sheets were measured using a noncontact laser interferometer.In addition,the cold-rolled SUS304 was subjected to heat holding at different temperatures and water quenching after bending to characterize its microstructure under tensile and compressive stress.The results show that,during the heating stage of the thermal cycle of laser lap welding,the partial penetration side of the SUS304 steel sheet generates compressive stress,which extrudes the material in the heat-affected zone to the outside of the back of the SUS304 steel sheet,thereby forming a bulge.The findings of these experiments can be of great value for controlling the distortion of the partial penetrated side of austenitic stainless steel sheet during laser non-penetration lap welding.

Optimization Mechanism of Mechanical Properties of Basalt Fiber-Epoxy Resin Composites by Interfacially Enriched Distribution of Nano-Starch Crystals

Fibre reinforced polymer composites have become a new generation of structural materials due to their unique advantages such as high specific strength,designability,good dimensional stability and ease of large-area monolithic forming.However,the problem of interfacial bonding between the resin matrix and the fibres limits the direct use of reinforcing fibres and has become a central difficulty in the development of basalt fibre-epoxy composites.This paper proposes a solution for enhancing the strength of the fibre-resin interface using maize starch nanocrystals,which are highly yield and eco-friendly.Firstly,in this paper,corn starch nanocrystals(SNC)were prepared by hydrolysis,and were deposited on the surface of basalt fibers by electrostatic adsorption.After that,in order to maximize the modification effect of nano-starch crystals on the interface,the basalt fiber-epoxy resin composite samples were prepared by mixing in a pressureless molding method.The test results shown that the addition of basalt fibers alone led to a reduction in the strength of the sample.Deposition of 0.1 wt%SNC on the surface of basalt fibers can make the strength consistent with pure epoxy resin.When the adsorption amount of SNC reached 0.5 wt%,the tensile strength of the samples was 23.7%higher than that of pure epoxy resin.This is due to the formation of ether bond homopolymers between the SNC at the fibre-epoxy interface and the epoxy resin,which distorts the originally smooth interface,leading to increased stress concentration and the development of cracks.This enhances the binding of basalt fibers.The conclusions of this paper can provide an effective,simple,low-cost and non-polluting method of interfacial enhancement modification.

Active Fault Tolerant Nonsingular Terminal Sliding Mode Control for Electromechanical System Based on Support Vector Machine

Effective fault diagnosis and fault-tolerant control method for aeronautics electromechanical actuator is concerned in this paper.By borrowing the advantages of model-driven and data-driven methods,a fault tolerant nonsingular terminal sliding mode control method based on support vector machine(SVM)is proposed.A SVM is designed to estimate the fault by off-line learning from small sample data with solving convex quadratic programming method and is introduced into a high-gain observer,so as to improve the state estimation and fault detection accuracy when the fault occurs.The state estimation value of the observer is used for state reconfiguration.A novel nonsingular terminal sliding mode surface is designed,and Lyapunov theorem is used to derive a parameter adaptation law and a control law.It is guaranteed that the proposed controller can achieve asymptotical stability which is superior to many advanced fault-tolerant controllers.In addition,the parameter estimation also can help to diagnose the system faults because the faults can be reflected by the parameters variation.Extensive comparative simulation and experimental results illustrate the effectiveness and advancement of the proposed controller compared with several other main-stream controllers.

An Integrated Control Framework for Torque Vectoring and Active Suspension System

Four-wheel independently driven electric vehicles(FWID-EV)endow a flexible and scalable control framework to improve vehicle performance.This paper integrates the torque vectoring and active suspension system(ASS)to enhance the vehicle’s longitudinal and vertical motion control performance.While the nonlinear characteristic of the tire model leads to a relatively heavier computational burden.To facilitate the controller design and ease the load,a half-vehicle dynamics system is built and simplified to the linear-time-varying(LTV)model.Then a model predictive controller is developed by formulating the objective function by comprehensively considering the safety,energy-saving and comfort requirements.The in-wheel motor efficiency and the power loss of tire slip are treated as optimization indices in this work to reduce energy consumption.Finally,the effectiveness of the proposed controller is verified through the rapid-control-prototype(RCP)test.The results demonstrate the enhancement of the energy-saving as well as comfort on the basis of vehicle stability.

Optimization of Fixture Number in Large Thin-Walled Parts Assembly Based on IPSO

There are lots of researches on fixture layout optimization for large thin-walled parts.Current researches focus on the positioning problem,i.e.,optimizing the positions of a constant number of fixtures.However,how to determine the number of fixtures is ignored.In most cases,the number of fixtures located on large thin-walled parts is determined based on engineering experience,which leads to huge fixture number and extra waste.Therefore,this paper constructs an optimization model to minimize the number of fixtures.The constraints are set in the optimization model to ensure that the part deformation is within the surface profile tolerance.In addition,the assembly gap between two parts is also controlled.To conduct the optimization,this paper develops an improved particle swarm optimization(IPSO)algorithm by integrating the shrinkage factor and adaptive inertia weight.In the algorithm,particles are encoded according to the fixture position.Each dimension of the particle is assigned to a sub-region by constraining the optional position range of each fixture to improve the optimization efficiency.Finally,a case study on ship curved panel assembly is provided to prove that our method can optimize the number of fixtures while meeting the assembly quality requirements.This research proposes a method to optimize the number of fixtures,which can reduce the number of fixtures and achieve deformation control at the same time.

High-Efficiency Dynamic Scanning Strategy for Powder Bed Fusion by Controlling Temperature Field of the Heat-Affected Zone

Improvement of fabrication efficiency and part performance was the main challenge for the large-scale powder bed fusion(PBF)process.In this study,a dynamic monitoring and feedback system of powder bed temperature field using an infrared thermal imager has been established and integrated into a four-laser PBF equipment with a working area of 2000 mm×2000 mm.The heat-affected zone(HAZ)temperature field has been controlled by adjusting the scanning speed dynamically.Simultaneously,the relationship among spot size,HAZ temperature,and part performance has been established.The fluctuation of the HAZ temperature in four-laser scanning areas was decreased from 30.85℃to 17.41℃.Thus,the consistency of the sintering performance of the produced large component has been improved.Based on the controllable temperature field,a dynamically adjusting strategy for laser spot size was proposed,by which the fabrication efficiency was improved up to 65.38%.The current research results were of great significance to the further industrial applications of large-scale PBF equipment.

Calculation and Analysis of TVMS Considering Profile Shifts and Surface Wear Evolution Process of Spur Gear

Profile shift is a highly effective technique for optimizing the performance of spur gear transmission systems.However,tooth surface wear is inevitable during gear meshing due to inadequate lubrication and long-term operation.Both profile shift and tooth surface wear(TSW)can impact the meshing characteristics by altering the involute tooth profile.In this study,a tooth stiffness model of spur gears that incorporates profile shift,TSW,tooth deformation,tooth contact deformation,fillet-foundation deformation,and gear body structure coupling is established.This model efficiently and accurately determines the time-varying mesh stiffness(TVMS).Additionally,an improved wear depth prediction method for spur gears is developed,which takes into consideration the mutually prime teeth numbers and more accurately reflects actual gear meshing conditions.Results show that consideration of the mutual prime of teeth numbers will have a certain impact on the TSW process.Furthermore,the finite element method(FEM)is employed to accurately verify the values of TVMS and load sharing ratio(LSR)of profile-shifted gears and worn gears.This study quantitatively analyzes the effect of profile shift on the surface wear process,which suggests that gear profile shift can partially alleviate the negative effects of TSW.The contribution of this study provides valuable insights into the design and maintenance of spur gear systems.

Multimode Design and Analysis of an Integrated Leg-Arm Quadruped Robot with Deployable Characteristics

To improve locomotion and operation integration, this paper presents an integrated leg-arm quadruped robot(ILQR) that has a reconfigurable joint. First, the reconfigurable joint is designed and assembled at the end of the legarm chain. When the robot performs a task, reconfigurable configuration and mode switching can be achieved using this joint. In contrast from traditional quadruped robots, this robot can stack in a designated area to optimize the occupied volume in a nonworking state. Kinematics modeling and dynamics modeling are established to evaluate the mechanical properties for multiple modes. All working modes of the robot are classified, which can be defined as deployable mode, locomotion mode and operation mode. Based on the stability margin and mechanical modeling, switching analysis and evaluation between each mode is carried out. Finally, the prototype experimental results verify the function realization and switching stability of multimode and provide a design method to integrate and perform multimode for quadruped robots with deployable characteristics.